A step - by – step approach

to constructing a simple
cam mechanism.

follower

cam handle

A cam is a mechanism which converts “round and round”

(rotary) motion to “up and down” (reciprocating) motion.

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 Step 1
I measured, marked out and cut the net of the box structure, inside which I am going to
assemble the cam mechanism.

overall length 40 cm

top of box
(and bottom)
are 10 cm2

width
30 cm
(3 x 10 cm)

flaps are
about the
width of
a ruler

Step 2
I scored and folded the box. At this stage, it is best to fix the box temporarily, so that I can
lay it flat again to work on it. I used little pieces of masking tape to hold it.
Instead of making my own box, I could have
used a ready made box like the one below from
YPO, or I could have brought a box from home.

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Step 3
I drilled a hole in the wheel I was using as a cam, and fitted my cam to the dowel axle.

I made the axle about 4 cm longer than the width of the box (so about 14 cm) so that it
would extend a little out from each side.

The further the axle is from

the centre, the more
exaggerated the movement
will be.

I could have used

specially shaped
cams as well as an
eccentric (off-centre)
wheel.

Step 4
Next I had to decide on the
position of the holes, one on
each side of the box, and one
on the top of the box.

! Be sure to position the two

side holes to allow the cam
to turn fully inside the box.

! The hole in the top will

probably be as far from the
back of the box as the side
holes, and equidistant from
the two sides.

I made the holes with a single

hole punch, and widened them
with a reamer.

SB…My Documents/Design & Technology/Cam Course/Cam Notes 1.doc 3

 Step 5

I cut a strip of
card, about
14 cm long
and 3 cm wide. The follower is a
length of dowel
I made a hole in with a small
the centre, and wooden wheel on
scored and the end.
folded two tabs.
The wheel helps it
This card will to sit on top of the
support and cam.
guide the
follower, so that
it moves up and
down, and not
side to side.

I fixed the card strip temporarily in place, and tested the mechanism to make sure it worked
as I intended. Having made any necessary adjustments, I marked where the card was to be
fixed. Then I disassembled the parts and made the fixings permanent.

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Step 6

I wanted to
make a crank
handle which I
could fix to one
end of the axle,
to turn the cam.
Here are just
three simple
ways of making
a handle.

A small A short strip

A short strip of wood
wooden wheel of corriflute
with a hole (1 cm2 cross section) can be used
with two holes drilled,
drilled off in the same
centre. A short one for the handle way as the
length of and one for the axle. length of
dowel acts as wood.
a handle.

Step 7

I used a tap washer to

hold the axle in position

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Some variations

This example is based on

exactly the same size box.

The card ‘lever’ is fixed to the

box at one end. It rises and
falls as the cam turns.

The longer the lever, the

greater the distance it
moves.

A wooden frame structure

is used here to support
three machanisms, side by
side.

The followers are guided by

holes in card triangles.

A wooden bead has been

fixed to one end of the axle.

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 This is another
example of three
cams, side by side.
It has been
constructed inside
a large cardboard
box.

The drop down

panel hides the
working
mechanisms as
well as supporting
the followers.

The axles on this vehicle

are not fixed to the centre
of the wheels.

The wheels act as

eccentric cams, causing
the vehicle to move up and
down as it is pulled along.

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 Possible resources

Materials / components Tools

• Card • Hand drill and bits

• Card boxes • Hacksaw

• Dowel • Single hole punch / reamer

• Wooden wheels (various sizes) • Scissors / snips

• Shaped cams • Ruler / safety ruler

• Tap washers • Glue gun

• Corriflute (small pieces for handles)

• Square section wood

• Adhesive (PVA, Pritt Stick, Glue

Gun)

• Masking tape

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